Howden 510 Compressor Coupling Alignment

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Howden 510 Compressor Coupling Alignment

Scope

The Verbrec Asset Management team was engaged to investigate the root cause of multiple quadraflex coupling failures (thermoplastic elastomer) and provide an engineering solution to improve asset reliability.

Project Summary

The LogiCamms Asset Management team was engaged to investigate the root cause of multiple quadraflex coupling failures (thermoplastic elastomer) and provide an engineering solution to improve asset reliability. Due to unplanned maintenance events, significant production losses and unplanned downtime was incurred. The scope of works included:

Review existing operational data relating to the quadraflex coupling assembly
Review specification of the quadraflex coupling
Communicate with key maintenance stakeholders to better understand historic failure events
Develop a set of acceptable alignment figures and tolerances to ensure all future lube oil pump to auxiliary gearbox shaft alignments are conducted consistently and within the recommended alignment tolerances
Develop a step-by-step procedure with the aim of providing technical guidance to maintenance technicians conducting shaft alignment work when replacing the quadraflex coupling assembly
Calculate the correct torque setting for the lube oil pump holding down bolts

SOLUTION
The overall solution comprised of the following activities:

Verified if the existing quadraflex coupling was suitable for the current type of service application and operating environment
Conducted torque calculations to determine the horsepower rating
Developed and approved an alignment procedure to ensure all maintenance technicians use the same procedure to achieve consistent and accurate results
Reduced the current level of coupling misalignment and lube oil system vibration
Updated the existing information in the maintenance management system to reflect the correct coupling specification

BENEFITS
Benefits as a result of the project activities include:

A reduction in lube oil pressure compressor trips as a result of fewer coupling failures
A reduction in unplanned maintenance and machine downtime
Life extension of the quadraflex coupling from a couple of weeks to 16,000 hours
An increase in production volume due to a reduction in offline machinery as a result of unplanned corrective coupling maintenance

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